Firewall Forward Kit

Baffles, cont'd ( 3 hrs )

Completed Right Air Ramp per Sect 47-10 and Right Forward Baffle at 47-11.  Added RTV strips to Left and Right Forward Baffles per Step 1 at Sect 47-12. 

Firewall Forward Kit

More Baffles ( 2 hrs )

Deburred holes and edges on several cowl baffle pieces for Sect 47-10 & -11.   Added nutplates and applied RTV to Vent Screen and Vent DL-03.

Firewall Forward Kit

Left Air Ramp and Air Filter Frame ( 3 hrs )

Assembled Left Air Ramp and Air Filter Frame - mix of deburring and cutting/sanding fiberglass.  Completed Sect 47-08 Steps 11-11, and Steps 1-9 at Sect 47-09 - except a few details.

fiberglass frame cut to size, nutplates riveted on

Left Forward Baffle nearing completion.

Firewall Forward Kit

RTV on Cowl Baffles ( 2 hrs )

Installed Brackets to engine per Steps 2-6 at Sect 47-06.  Applied Red RTV (high temp) to Aft Baffles per 47-07.   Tip by Vans to use masking tape works well to provide neat "stripes".

fwd bracket left finger tight until baffle installed

1 of  2 done  - masking tape helps keep mess to minimum.

Firewall Forward Kit

Cowl Baffles cont'd ( 2 hrs )

Completed Cylinder 3 Baffle and RH Aft Baffle at 47-05, Steps 1-5.  I've decided to not prime or paint the cowl baffles after checking what several other builders have done (or not done).  Prepped Aft Center and Center Brackets per Sect 47-06 - these I decided to prime and paint ( Rustoleum Professional Stainless Steel).

rear side of  Right Aft Baffle

deburred, buffed, then primed and finish coated brackets w/
Rustoleum Professional Stainless Steel color used
elsewhere on firewall

Firewall Forward Kit

Continued Cowl Baffles ( 4 hrs )

Completed Left Aft Baffle per Steps 1-8 @ Sect 47-03, and Right Aft Baffle Steps 1-11 @ 47-04.  Variety rivets, Mach C'sink, and dimpling for "entertainment".

Firewall Forward Kit

Cowl Baffles ( 3 hrs )

Cut 6 lengths of 1" dia. PVC pipe to exactly 2.125" per "Simulating the Propeller for Fitting the Cowl" (re: Vans website at Construction FAQs).  Attached Spinner Backplate with 6 std hardware 1/2-20 x 3" bolts. Ready to start fitting Cowl in place per Sect 45 in Finish Kit.   Decided instead to do Sect 47 Cowl Baffles - seemed ready to do more deburring and riveting.  Completed Sect 47-02, Steps 1-8 Cylinder Baffles with addition of doublers.

spacers at 2 1/8" simulate actual CS Prop Hub

first parts of Cowl Baffle riveted...

Firewall Forward Kit

Fuel Injection Servo installation ( 2 hrs )

Installed Avstar Fuel Inj Servo model AVX-5VA1 (serial # AV039955, part list # AVX3015006-1) to engine sump/air box with gasket #66224. All provided with engine from Lycoming.  Attached and torqued fuel lines.  Also consulted with Vans Tech Support, and decided to proceed with Sect 45 Cowling (from Finish Kit) next,  prior Sect 44: Spinner and Propeller.  Vans website provides Construction FAQs including "Simulating Propeller for Fitting the Cowl" - which positions the spinner backplate for alignment of cowl without mounting Prop, Hub, and Spinner.

beauty shot...  mixture lever side

throttle lever side

lever will be changed about 90 deg clockwise (down and back)

model and serial number plate on bottom

Firewall Forward

Alternator ( 3 hrs )

Installed Alternator per Sect 43-12 Steps 1-6 (ref prep in March 17 log).  Per instructions, delayed setting belt tension until Sect 51-06, after propeller installed, etc.   Safety wire took a trial run, but getting closer to "fun".  Also getting better at installing adel (or cushion) clamps using temporary safety wire, and "Cushioned Clamp Installation Pliers".  Thanks Vans Tech Support for recommending applying silicone spray to enable sliding clamps into position during assembly.

routed alternator power wire along side of engine case

double clamp on mount tube routes wire to firewall

Firewall Forward Kit

Wiring to Starter & misc ( 3 hrs )

Routed WH-P16 Starter Wire from starter relay at firewall to Sky-Tec starter (model 149-12XLT, pre-installed by Lycoming) per Sect 43-11, Steps 1-7.  The "Detail A" to install mounting clamp and VA-163 to engine case was challenging due to tight confines.  Added adel clamps several locations per 43-10, but waiting on most until actual wiring is ready to be routed (so don't need to do over !).  Beginning to install Alternator per 43-12.  Plane Power P/N AL12-E160N,  S/N H-R061143 (Vans ES Alternator Deluxe, part of kit.   Features internal regulator "crowbar" with over-voltage protection.

label on Starter

starter wires routed via clamp attached to engine case 

showing starter cable routing, and VA-163 bracket 
(throttle cable support) above sump, along engine case

Plane Power Alternator kit via Vans

label on PMAG from EMAG (replaced RH Slick Magneto
in Lycoming  option (via Vans bundled order with propeller)

Firewall Forward Kit

Wingtip Wiring Rev 2, and Cushioned clamps (1 hr )

Revised black (ground) wire routing per Sect 19-02 (Rev 2 on 11/20/17) for Wingtip Lighting, Steps 4 & 5 (Vans changed ground wire Blk L422 from ground at outer Rib, to instead attach to LED Landing Light, apparently to minimize interference with Magnetometer, etc).   Installed 4 adel clamps on engine per Step 1 at 43-10 for routing spark plug wires...later.

2 cushioned (adel) clamps mounted each side of engine

Firewall Forward Kit

Dehydrator Plugs ( 1 hr )

Installed 4 Dehydrator Plugs (18mm).  Needed trip to hardware store to get a long reach 7/8" socket for the aviation spark plugs.   Terry Moushon (RV-10 builder and Tech Counselor) confirmed only four would be needed (one per cylinder).  I'd need 14mm automotive size for the other 4 locations (due to E Mag installation).

dehydrator plugs prevent rust and corrosion in engines
while in storage.  Contain silica gel which turns from
blue to pink when moisture is absorbed. Reusable
and refillable. The pink silica gel may be reactivated
(after removing from reservoir) by heating

Firewall Forward

Fuel Flow Transducer ( 1 hr )

Installed IE Dynon FF  Fuel Flow Transducer, including VA 102 Fuel Press Line and FF00019 Hose Ass'ly to Fuel Pump per Steps 1-3 at Sect 43-09, and Fig 1-4 at Sect 49-04.  Installed EA LW-75444 Sniffle Valve to bottom of the oil sump per Step 4 at Sect 43-09.

Firewall Forward

Propeller Gov ( 1 hr )

Mounted Hartzell S-1-79 Propeller Gov ( serial # G3709NJ) per Steps 3-6 at Sect 43-07.  Small adjustment to arm position needed by rotation of faceplate a few degrees.  After pic, removed Bracket Ass'ly until Sect 47.